Mo containing catalyst, a preparation method and a method for preparing methyl mercaptan

ABSTRACT

A method is described to prepare a Mo containing supported catalyst comprising TeO 2  as active promoter and a process for preparing methanethiol in the presence of said catalyst.

The invention relates to a process for the preparation of a Mo and Te containing catalyst, and the catalyst itself, useful for methanethiol synthesis from syngas preferably containing high amounts of H₂S.

THE PRIOR ART

As an important chemical educt for the production of methionine, pesticides and medicine, methanethiol is predominantly prepared by the reaction of hydrogen sulfide with methanol. For example, U.S. application Ser. No. 856,232 discloses a methanethiol synthesis method based on the reaction of hydrogen sulfide with methyl alcohol or diethyl ether; FR appl. 93,112,491 discloses a preparation method based on the reaction of methyl thio-ether with hydrogen over a transition metal catalyst; EP167,354 discloses a synthesis pathway with a catalyst based on titanium dioxide support and containing NiO or MoO₃ as active components for the reaction of hydrogen sulfide with carbon monoxide; Chinese patent applications CN1207957 and CN98118187.2 disclose two catalysts for methyl mercaptan synthesis from syngas containing high amounts of H₂S, in which the active component Mo—S—K is formed from the precursor of K₂MoS₄ or (NH₄)₂MoS₄ plus one potassium salt; WO 2005/040082 discloses two Mo—O—K/SiO₂ catalysts for the methanethiol synthesis, wherein the promoters are chosen from the group consisting of oxides of Co, Ni, Fe, Mn or La and Ce, whereby the active component Mo—O—K is formed from K₂MoO₄ or (NH₄)₆Mo₇O₂₄.4H₂O plus a potassium salt as precursors.

STATEMENT OF THE INVENTION

The object of this invention is the preparation of catalysts with high activity and selectivity for the one-step methanethiol synthesis from syngas, preferably containing high amounts of H₂S. This means preferably a content in the range of 50 to 80 Vol. % H₂S.

DETAILED DESCRIPTION OF THE INVENTION

The catalyst according to the invention comprises active components, active promoters and a support material. It is directed to a supported catalyst comprising

-   -   a) a Mo containing and a K containing compound as active         components, whereby Mo and K can be constituents of the same         compound,     -   b) a promoter, wherein the promoter comprises TeO₂ and     -   c) an oxidic carrier.

Said active component is preferably a Mo—O—K-based active center. Precursors of the Mo and K containing compounds are

-   -   a) K₂MoO₄ or     -   b) (NH₄)₆Mo₇O₂₄.4H₂O denoted by MoO₃ plus a potassium salt         denoted as a K₂O precursor or     -   c) MoO₃ plus one kind of potassium salt, said potassium compound         is at least one chosen from the group comprising K₂CO₃, KOH and         CH₃COOK or any other potassium containing compound being known         as a K₂O precursor.

Said promoter is a Te-containing compound denoted by TeO₂ whereby H₆TeO₆ (H₂TeO₄×2 H₂O) or any other Te-containing salts or compounds being suitable as TeO₂-precursors are used, also a potassium salt of said telluric acid H₆TeO₆.

Said support is preferably SiO₂ or an oxidic carrier such as TiO₂, ZrO₂, Al₂O₃, Al₂O₃—SiO₂, zeolites, pure or mixtures of said metal oxides.

For the catalyst TeO₂—K₂MoO₄/SiO₂ (prepared from K₂MoO₄) the weight ratio is TeO₂/K₂MoO₄/SiO₂=(1-20)/(1-50)/100, more preferably (3-12)/(15-30)/100, for the catalyst TeO₂—MoO₃—K₂O/SiO₂ (prepared for example from (NH₄)₆Mo₇O₂₄.4H₂O and a potassium containing salt) the weight ratio is TeO₂/MoO₃/K₂O/SiO₂=(1-20)/(1-50)/(1-50)/100, more preferably (3-12)/(15-30)/(8-20)/100.

-   -   The invention is also directed to a method to prepare a catalyst         according to claim 1, comprising the steps:     -   a) impregnating said carrier in more than one step with one or         more aqueous solutions comprising a Te containing compound which         acts as a Teo₂ precursor and a K containing compound which acts         as a K₂O precursor and (NH₄)₆MO₇O₂₄ or MoO₃ as Mo containing         compounds; or     -   b) impregnating said carrier in more than one step with one or         more aqueous solutions comprising a Te containing compound which         acts as a TeO₂ precursor and K₂MoO₄;     -   c) drying the received impregnated carrier; and     -   d) optionally treating said impregnated carrier with H₂ or         syngas (CO+H₂) or a syngas and H₂S at elevated temperatures,         preferably 200 to 450° C.

Products which are not pre-treated with said gases are also part of the invention.

The formulas of catalysts prepared are expressed as TeO₂/K₂MoO₄/carrier or Teo₂/MoO₃/K₂O/carrier.

Being exposed to a hydrogen sulphide containing atmosphere the oxidic compounds of Mo, K, Te comprised in the catalyst are converted into sulphides in complete or partially. That means that oxides or sulfides or mixtures of both are contained on the catalyst carrier.

XPS-spectra of said sulfided catalysts modified by different amounts of TeO₂ show, that there are higher relative concentrations of Mo⁴⁺ and Mo⁵⁺ on the surface of the TeO2-promoted catalysts as compared to K₂MoO₄/carrier (especially SiO₂), accompanied by lower concentrations of Mo⁶⁺ at the same time. The catalyst contains TeO₂ in the range from 5 to 20, especially 7 to 12 wt. %, based on the total weight of the catalyst.

In order to achieve a better distribution of the active component and the promoter on the surface of the carrier, at least one chelating reagent is preferably present in the impregnation process. Said chelating reagents are chosen from carboxylic acids such as citric acid, tri-ammonium citrate, L-glutamic acid, tartaric acid and complexing agents such as ethylenediaminetetraacetic acid (EDTA), while the amount of chosen chelating agent added is 0.1-0.6 times by weight as much as that of the carrier and more preferably is 0.3-0.6 by weight. Ammonia should be added to adjust the pH value of the impregnating liquor to 8-10, the preferred operating procedure is an at least two step impregnation method comprising:

(1) when K₂MoO₄ is chosen as the precursor of the active compound, a given quantity of H₆TeO₆ according to the desired weight ratio is dissolved in a given quantity of distilled water to produce an aqueous solution, with which an according quantity of carrier is impregnated for 8-10 h, then dried at 100-135° C. for 4-6 h to produce an intermediate product; a given quantity of at least one chelating reagent and K₂MoO₄ are then dissolved in a given quantity of distilled water to produce an aqueous solution, into which a suitable amount of ammonia water is added to adjust the pH value to 8-10. The intermediate product produced above is impregnated with said solution for 8-10 h, finally said impregnated material is dried at elevated temperatures, especially at 110-135° C. for 4-6 h.

(2) When (NH₄)₆Mo₇O₂₄.4H₂O plus one of the above-mentioned potassium compounds are chosen as the precursors of the active compound, the order of preparation is preferably as follows: first) a quantity of chosen potassium compound and a given quantity of H₆TeO₆ according to the desired weight ratio of Mo and Te are dissolved in a given quantity of distilled water to generate an aqueous solution. An according quantity of carrier is impregnated with said solution for 8-10 h, then dried at elevated temperatures, especially at 100-130° C. for 4-6 h to form a H₆TeO₆—K/SiO₂ intermediate product; a quantity of a chosen chelating reagent and (NH₄)₆Mo₇O₂₄.4H₂O are then dissolved in a prescribed amount of distilled water to produce an aqueous solution, the pH value of which is adjusted to 8-10, by adding a suitable amount of ammonia water. Said intermediate product is then impregnated with said solution for 8-10 h, followed by drying it at elevated temperatures, especially at 110-135° C. for 4-6 h.

It is also possible to change the step sequence:

(3) A given quantity of (NH₄)₆Mo₇O₂₄.4H₂O and a given quantity of H₆TeO₆ are dissolved in a given quantity of distilled water to generate an aqueous solution. A given quantity of SiO₂ is impregnated for 8-10 h, with said solution then dried at elevated temperatures, especially at 100-130° C. for 4-6 h to form a Mo—O—Te/SiO₂ intermediate product; a given quantity of potassium compound is dissolved in a given quantity of distilled water to produce an aqueous solution, into which a given quantity of the chosen chelating agent and ammonia water are added to adjust the pH value of the solution to 8-10, with which the Mo—O—Te/SiO₂ produced above is impregnated for 8-10 h, followed by drying at 110-135° C. for 4-6 h.

A continuous process for the manufacture of methyl mercaptan is successfully carried out by reacting a mixture of carbon oxides, sulphur or hydrogen sulphide and hydrogen at elevated temperatures and pressures in the presence of the above described catalysts.

The feed gas has preferable a hydrogen sulphide content in the range of 50-80 Vol. %.

It is preferred to feed the reactants carbon oxide, sulphur, hydrogen sulphide and hydrogen to the reactor in a molar ratio from 1/0/1/0 to 1/10/10/10, preferably from 1/0/2/2 to 1/0/10/10.

The reaction conditions as well as purification of the product and the recycling of non reacted compounds are generally known (U.S. Pat. No. 4,665,245/EP-A-104507; WO 2005/040082).

The catalyst should be pretreated with H₂ or syngas(CO+H₂) for 8-10 h preferably followed by sulfiding with H₂S prior to the catalytic conversion of carbon monoxide, hydrogen and hydrogen sulphide to methanethiol to obtain the TeO₂ component of the promoter.

The evaluation of the catalytic performance of the catalyst in the present invention was carried out in a fixed-bed tubular reactor with 0.5 ml of catalyst per pass. The experiments were performed under the reaction conditions of CO/H₂/H₂S=1/1/2, 300° C., 0.2 MPa and GHSV=2000 h⁻¹. The products were analyzed by GC. All data were obtained after steady state conditions were achieved.

The following examples illustrate the present invention.

Example 1

Under stirring 0.648 g of H₆TeO₆ were fully dissolved in 10.0 ml of distilled water, the pH value of the aqueous solution of H₆TeO₆ thus prepared was measured to be 4.1, then 5.000 g of SiO₂ were impregnated with the aqueous solution of H₆TeO₆ at room temperature for 8 h, followed by drying at 120° C. for 5 h to produce a dried intermediate product.

Under stirring 2.068 g of K₂MoO₄ were fully dissolved in 5.0 ml of distilled water to produce a K₂MoO₄ aqueous solution, into which 5 ml of NH₃.H₂O were added, the pH value of the aqueous solution was measured to be 11.40, then, under stirring 3.000 g of citric acid were added to the aqueous solution of K₂MoO₄ plus NH₃.H₂O, the pH value of the K₂MoO₄ plus NH₃.H₂O solution was measured to be 9.26. Finally, the intermediate product prepared in step (1) was impregnated with the solution containing citric acid K₂MoO₄ plus NH₃.H₂O at room temperature for 10 h, followed by drying at 120° C. for 5 h to generate a catalyst comprising TeO₂/K₂MoO₄/SiO₂, showing the weight ratio of 9/25/100. The evaluation results of the catalyst thus prepared are shown in table 1.

Example 2

(1) Under fast stirring, 1.468 g of K₂CO₃ and 0.648 g of H₆TeO₆ were fully dissolved in 10 ml of distilled water to form an aqueous solution, with which 5.000 g of SiO₂ were impregnated at room temperature for 9 h, and finally dried at 125° C. for 4 h to generate an intermediate product.

(2) 1.534 g of (NH₄)₆Mo₇O₂₄.4H₂O were fully dissolved in 5.0 ml of distilled water under agitating to form an aqueous solution, to which 2.000 g of tri-ammonium citrate were added. Subsequently, a suitable amount of NH₃.H₂O was added to adjust the pH of the solution to 9.05. The intermediate product prepared in step (1) was impregnated with said solution at room temperature for 9 h and finally dried at 125° C. for 4 h to produce the catalyst K₂O/MoO₃/TeO₂/SiO₂, showing the weight ratio of 20/25/9/100. The evaluation results of the catalyst thus prepared are shown in table 1.

Example 3

The catalyst was prepared according to the method described in Example 1, but 2.000 g of tartaric acid was used as chelating reagent and the carrier SiO₂ was replaced by γ-Al₂O₃. The evaluation results of the catalyst thus prepared are shown in table 1.

Example 4 and 5

The catalyst was prepared according to the method described in Example 1, but the quantity of H₆TeO₆ was changed to be 0.486 g and 0.432 g respectively, and the chelating reagents used was EDTA in both cases, the weight ratio of the final catalysts thus prepared were TeO₂/K₂MoO₄/SiO₂=6.75/25/100 and TeO₂/K₂MoO₄/SiO₂=6/25/100 respectively. The evaluation results of the catalysts thus prepared are shown in table 1.

Example 6

The catalyst was prepared according to the method described in Example 1, but 5.000 g of TiO₂ was used as the carrier. The amount of H₆TeO₆ and the amount of K₂MoO₄ were replaced by 0.142 g and 0.827 g, respectively. The final catalyst prepared was TeO₂/K₂MoO₄/TiO₂=2/10/100.The evaluation results of the catalyst thus prepared are shown in table 1.

Example 7

The catalyst was prepared according to the method described in Example 6, but 5.000 g of ZrO₂ was used as the carrier. and the amount of H₆TeO₆ and K₂MoO₄ was replaced by 0.071 g and 0.414 g respectively. The final catalyst prepared was TeO₂/K₂MoO₄/ZrO₂=1/5/100. The evaluation results of the catalyst thus prepared are shown in table 1.

Example 8

The catalyst was prepared according to the method described in Example 2, but 5.000 g of the mesoporous molecular sieve MCM-41 was used as the carrier, and the amount of K₂CO₃, H₆TeO₆ and (NH₄)₆Mo₇O₂₄.4H₂O was replaced by 1.835 g, 1.080 g and 2.454 g, respectively. The final catalyst prepared was K₂O/MoO₃/TeO₂/MCM-41=25/40/15/100.

The evaluation results of the catalysts modified with different amounts of TeO₂ for methanethiol synthesis from high H₂S containing feed gas are listed in table 1.

As it can be seen the addition of TeO₂ to K₂MoO₄/SiO₂ catalyst increases evidently the activity of the catalysts, which can find expression in the significant change of conversion of CO and the yield of CH₃SH. The conversion of CO reaches a maximum with 61.5% and a yield of methanethiol of 0.39 g.ml_(cat) ⁻¹.h⁻¹. Obviously, both the conversion of CO and the yield of methanethiol do not correspond linearly or regularly as function of the amount of TeO₂ added.

TABLE 1 The evaluation results of the catalysts in examples 1-8. Conv. Example Selectivity (%) CO₂/ Yield (g · ml_(cat) ⁻¹ · h⁻¹) of CO (catalyst) CH₄ CH₃SH COS CO₂ CH₃SH CH₄ CH₃SH COS CO₂  (%) 1, K₂MoO₄/TeO₂/SiO₂ = 25/9/100 0.23 55.21 10.70 33.86 0.61 0.0005 0.38 0.09 0.21 59.29 2, K₂O/MoO₃/TeO₂/SiO₂ = 15/25/9/100 0.25 55.15 11.30 33.30 0.60 0.0005 0.35 0.09 0.19 57.26 3, K₂MoO₄/TeO₂/γ-Al₂O₃ = 25/9/100 0.30 48.70 17.91 33.08 0.68 0.0005 0.24 0.09 0.21 56.02 4, K₂MoO₄/TeO₂/SiO₂ = 25/6.75/100 0.24 54.74 10.72 34.90 0.60 0.0005 0.35 0.09 0.21 56.02 5, K₂MoO₄/TeO₂/SiO₂ = 25/6/100 0.24 54.50 10.50 35.02 0.66 0.0005 0.36 0.09 0.22 57.52 6, K₂MoO₄/TeO₂/TiO₂ = 10/2/100 0.08 48.40 14.05 37.47 0.77 0.0005 0.31 0.09 0.24 48.4 7, K₂MoO₄/TeO₂/ZrO₂ = 5/1/100 0.09 48.17 17.84 33.90 0.70 0.0005 0.27 0.10 0.19 39.6 8, K₂O/MoO₃/TeO₂/MCM-41 = 25/40/15/100 0.07 51.28 11.83 36.82 0.72 0.0005 0.39 0.09 0.28 61.5

Example 9

FIG. 1 shows X-ray diffractograms of the catalyst TeO₂—K₂MoO₄/SiO₂ prepared by drying of the catalyst at 150° C. and calcination at 400° C. as compared to the starting materials and the catalysts K₂MoO₄/SiO₂ and CoO—K₂MoO₄/SiO₂ [A) carrier SiO₂; B) H₆TeO₆; C) K₂MoO₄/SiO₂; D) TeO₂—K₂MoO₄/SiO₂ (prepared with citric acid; drying at 150° C.); E) TeO₂—K₂MoO₄/SiO₂ (prepared with HNO₃ and without chelating reagent); F) CoO—K₂MoO₄/SiO₂; G) TeO₂—K₂MoO₄/SiO₂ (calcined at 400° C.) ; H) CoO—K₂MoO₄/SiO₂ (calcined at 500° C)]. The diffractograms clearly demonstrate the distinct nature of the Te-containing catalysts as compared to other catalysts prepared on the basis of the system K₂MoO₄/SiO₂ 

1. A supported catalyst comprising a) a Mo and a K compound as active components, whereby Mo and K can be constituents of the same compound, b) a promoter, wherein the promoter comprises TeO₂ and and c) an oxidic carrier
 2. The catalyst according to claim 1, wherein the weight ratios of the components are TeO₂/KMoO₄/carrier=(1-20)/(1-50)/100 or TeO₂/MoO₃/K₂O/carrier=(1-20)/(1-50)/(1-50)/100.
 3. The catalyst according to claim 2, wherein the weight ratios of the components are (1) TeO₂/KMoO₄/carrier=(3-12)/(15-30)/100 or (2) TeO₂/MoO₃/K₂O/carrier=(3-12)/(15-30)/(8-20)/100
 4. The catalyst according to claim 1, wherein the carrier is selected from the group consisting of SiO₂, Al₂O₃, TiO₂, Al₂O₃—SiO₂,ZrO₂, zeolites, carbon containing materials and mixtures thereof.
 5. The catalyst according to claim 1, wherein the catalyst contains an active Mo—O—K center.
 6. The catalyst according to claim 1, wherein the catalyst is sulfided by exposing to an hydrogen sulphide containing atmosphere.
 7. The catalyst according to claim 1, wherein the TeO₂ content is in the range from 1 to 20 wt. %.
 8. A method to prepare a catalyst according to claim 1, comprising the steps: a) impregnating said carrier in more than one step with one or more aqueous solutions comprising a Te containing compound which acts as a TeO₂ precursor and a K containing compound which acts as a K₂O precursor and (NH₄)₆Mo₇O₂₄ or MoO₃ as Mo containing compounds; or b) impregnating said carrier in more than one step with one or more aqueous solutions comprising a Te containing compound which acts as a TeO₂ precursor and K₂MoO₄;
 9. A method according to claim 8, comprising the steps: a1) impregnating the carrier with an aqueous solution of a Te-containing compound which is a TeO₂ precursor, drying said impregnated carrier at elevated temperatures to produce an intermediate product (a). a2) impregnating said product (a) with an aqueous solution of K₂MoO₄ to produce a product (b) with weight ratios of the components according to ratio (1) and drying the said product (b) at elevated temperatures; or b1) impregnating the carrier with an aqueous solution of a Te-containing compound which is a TeO₂ precursor and of a K-containing compound which is a K₂O precursor to form an impregnated carrier, drying said impregnated carrier at elevated temperatures to produce an intermediate product (c); and b2) impregnating said intermediate product (c) with an aqueous solution of (NH₄)₆Mo₇O₂₄.4H₂O to produce a catalyst with weight ratios of the components according to ratio (2) and drying said-impregnated product (d), whereby the pH-value during the second impregnation steps a2) and b2) is adjusted to a range of 8 to
 10. 10. The method according to claim 9, whereby adjusting the pH value is achieved by adding a suitable amount of ammonia water or ammonia.
 11. The method according to claim 9, whereby at least one chelating reagent is added during impregnation with the Mo containing compound.
 12. The method according to claim 9, whereby the chelating reagent is added in a weight of 0,1 to 0,6/1 relative to the carrier.
 13. The method according to claim 9, whereby the chelating reagent is chosen from the group of citric acid, tri ammonium citrate, L-glutamic and tartaric acid or ethylendiaminetetraacetic acid (EDTA).
 14. The method according to claim 8, whereby the catalyst is sulfided by exposing to a hydrogen sulphide containing atmosphere.
 15. A method for preparing methyl mercaptan in a catalytic process by reacting a carbon oxide, selected from the group consisting of CO, CO₂, and mixtures thereof, sulphur and/or hydrogen sulphide, and hydrogen, as reactants whereby the reaction takes place in the presence of a supported catalyst comprising a) a Mo and a K compound as active components, whereby Mo and K can be constituents of the same compound, b) a promoter, wherein the promoter comprises TeO₂ c) an oxidic carrier.
 16. The method of claim 15, wherein the weight ratios of the components are TeO₂/K₂MoO₄/Carrier=(3-12)/(15-30)/100 or TeO₂/MoO₃/K₂O/carrier=(3-12)/(15-30)/(8-20)/100.
 17. The method of claim 15 wherein the carrier is selected from the group consisting of SiO₂, TiO₂, Al₂O₃, Al₂O₃—SiO₂, zeolites, carbon containing materials and mixtures thereof.
 18. The method of claim 15, wherein the reactants are fed to the reaction in a molar ratio from 1:0:1:0 to 1:10:10:10.
 19. The method of claim 15, wherein the molar ratio of the reactants range from 1:0:2:2 to 1:0:10:10. 